Gas Tungsten Arc Welding Process (GTAW) is widely used in fabrication of Aluminium and Aluminium Alloy material when precision is considered as a prime importance. Deformations in the object undergoing welding are one of the foremost problems encountered in the welding industry. Thus it is often required to study the factors which affect the deformations produced during welding to avoid errors in the geometry. Present investigation highlights Experimental and Finite Element Analysis of a Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters.Finite Element Method (FEM) has been employed to do the transient thermal and structural analysis of the assembly. The Finite Element Analysis has been done on ANSYS 14.5 Workbench. Number of factors is liable to produce effects in the job during the welding operation. Aim of this paper is the effect of welding parameters like as welding current, shielding gas flow rate and welding speed with mechanical Properties like tensile strength and hardness. After that finite element analysis for temperature distribution and distribution of the stresses in the welded Aluminium alloy plate. The results show that the larger the Welding current and smaller welding speed will lead to the maximum residual tensile stress. Therefore a residual stress will arise from the restraint position. The ultimate residual stress of weldment is determined by material yield strength at different temperature. The higher yield strength at different temperature has higher material residual stress. Because of its higher thermal conductivity, aluminium alloy test specimens have small temperature differential.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 10, 2015 | ISSN (online): 2321-0613
All rights reserved by www.ijsrd.com 639
Experimental and Finite Element Analysis of Single-V Groove Butt Weld on
Weld Pool Geometry of Aluminium Alloy Plate under Different Joint
Parameters
Sushil Kumar Maurya1
A. K. Jain2
1
Research Scholar (Machine Design) 2
Associate Professor
1,2
Department of Mechanical Engineering
1,2
Jabalpur Engineering College, Jabalpur (MP), India
Abstract— Gas Tungsten Arc Welding Process (GTAW) is
widely used in fabrication of Aluminium and Aluminium
Alloy material when precision is considered as a prime
importance. Deformations in the object undergoing welding
are one of the foremost problems encountered in the welding
industry. Thus it is often required to study the factors which
affect the deformations produced during welding to avoid
errors in the geometry. Present investigation highlights
Experimental and Finite Element Analysis of a Single-V
Groove Butt Weld on Weld Pool Geometry of Aluminium
Alloy Plate under Different Joint Parameters.Finite Element
Method (FEM) has been employed to do the transient
thermal and structural analysis of the assembly. The Finite
Element Analysis has been done on ANSYS 14.5
Workbench. Number of factors is liable to produce effects in
the job during the welding operation. Aim of this paper is
the effect of welding parameters like as welding current,
shielding gas flow rate and welding speed with mechanical
Properties like tensile strength and hardness. After that finite
element analysis for temperature distribution and
distribution of the stresses in the welded Aluminium alloy
plate. The results show that the larger the Welding current
and smaller welding speed will lead to the maximum
residual tensile stress. Therefore a residual stress will arise
from the restraint position. The ultimate residual stress of
weldment is determined by material yield strength at
different temperature. The higher yield strength at different
temperature has higher material residual stress. Because of
its higher thermal conductivity, aluminium alloy test
specimens have small temperature differential.
Key words: Aluminium Alloy Plate, Single-V Groove,
Welding Parameter, Welding Joint, Mechanical Properties,
FEA, ANSYS
I. INTRODUCTION
Aluminium alloys has been found wide application in
industry as it has many virtues, such as light weight, easy
machining, nontoxic, excellent ductility, good corrosion
resistance and high strength ratio. However, physical and
mechanical properties of aluminium alloy has been blamed
for some defects in its welding, such as hot cracking,
deformation, porosity and decrease in the strength of heat
affected zone. Among them, deformation, besides the
influence of material properties such as high coefficient of
thermal expansion and thermal conductivity is also closely
related to welding processes. As for the appearance of hot
cracking, apart from the influence of material alloy content,
it is also connected to contraction stress resulting from
heating and cooling in welding [1,2]. However, due to rapid
local heating, the distribution of internal temperature in the
weldment is uneven. With their larger thermal conductivity
and lower high - temperature strength often lead to greater
stress and deformation of the welded components, which
can result in a series of issues such as low intensity,
instability of the joint in size and small ductile deformation,
thus their further development and applications. With the
development of technology, understanding of stress and
deformation has not been dependent solely on the physical
measurements. It can be also predicted using finite element
methods quickly and accurately. At present, the vast
majorities of research on the welding numerical simulations
are reported to be aiming at MIG welding, but less at the
TIG, Particularly at gas tungsten arc welding. In this paper,
the GTAW process of aluminium alloy plates was
numerically analysis by using finite element method, and
stress after welding was predicted. Finally, the mechanical
properties of welded materials are measured in terms of
tensile strength and Brinell hardness using experimentally.
After that temperature distribution and distribution of the
stresses in the welded aluminium alloy plate during the
welding operation are investigate by finite element method.
Tungsten Inert Gas (TIG) welding is a welding
process used for high quality welding of a variety of
materials with the coalescence of heat generated by an
electric arc established between a non- consumable tungsten
electrode and the metal. The process of melting the work
piece and filler rod to form a weld results in the formation of
fumes and gases. Argon used as shielding gases for better
welding because they do not chemically react. The inert gas
 Shield the welding area from air, preventing oxidation
 Transfer the heat from electrode to metal
 Helps to start and maintain a stable arc due to low
ionization potential
Fig. 1: (a) TIG welding machine

2. Experimental and Finite Element Analysis of Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters
(IJSRD/Vol. 3/Issue 10/2015/137)
All rights reserved by www.ijsrd.com 640
Fig.1. (b) Argon gas cylinder
The finite element method cuts the structure into
small number of elements and interconnecting the elements
through nodes. By assembling all the element matrices, it
will give the total displacement of the structure. In transient
thermal analysis, temperature field (T) of welded plate is a
function of time (t). Thermal conduction will take place on
the metal. Therefore three dimensional transient heat
transfer equation is
Here Qint is the internal heat source, ρ, Cp, k are
density, specific heat and thermal conductivity of material
respectively. During the welding, the heat will be lost due to
radiation and convection. The convection and radiation heat
losses are determined by the following equations
Here, T0 is atmospheric temperature is considered
as initial temperature, T is surface temperature of plate, h is
Convective heat transfer coefficient, σ is the Stefan-
Boltzmann constant, ℰ emissivity. Convection boundary
condition applied all surfaces of metal plate except bottom
surface of the plate. If system is in equilibrium with
surroundings then it should have surrounding temperature.
In welding, the applied heat through the welding torch is lost
by conduction, convection and radiation. Conductivity is the
ability to conduct the heat. In welding, the temperature is
higher in weld region, so the metal conducts the heat from
higher region to lower region to bring the metal equilibrium.
Conduction is mainly depends on thermal conductivity of a
metal. Convection is heat transferred by moving fluid. The
plate is static position and the moving fluid is atmospheric
air. The atmospheric air is taking the heat from metal to
bring the metal equilibrium to surrounding temperature.
Total heat loss = convection + radiation
Butt-welding is the process of joining two pieces of
material together along a single edge in a single plane. This
process can be used on many types of materials, though
metal and thermoplastics are the most common. When two
sheets of aluminium are laid side-by-side and joined
together along a single joint, this is an example of butt-
welding.
Past researches on aluminium alloy welding mainly
gave priority to the changes in properties of hot cracking
and heat affected zones and investigated residual stress,
which was an important factor leading to hot cracking. By
taking heat treatable aluminium alloy Al-5083 as objects of
study, after a single V- groove welding on aluminium alloys
at Vee preparation angles, this study investigated the
correlation between weldment residual stress and welding
processes and material mechanical properties. This research
adopted as to measure the mechanical Properties like tensile
strength and hardness. After that finite element analysis for
temperature distribution and distribution of the stresses in
the welded Aluminium alloy plate. We also hoped that
results of this research could be used by our counterparts for
reference.
II. DESIGN OF EXPERIMENT APPROACH
This research mainly investigated the residual stress and
temperature distribution of weldment at single-V groove
angles in restrained conditions. Therefore, guided by the
principle of maintaining a complete weld bead, we kept
certain heat input in welding (welding current, welding
speed and gas flow rate were variable) but adjusted filler
metal feed according to the angles of a single-V groove.
A. Base Metals
The base metals used in this experiment were aluminium
alloy Al5083.The dimensions of base metal were 200mm
X50mm X5mm (Length X Width X Thickness). The
nominal chemical composition of this alloy is presented in
table.1.
Fig. 2: Base Metal
Materials Mg Mn Si Fe Zn Cr Ti Cu
Al5083 4.45 0.7 0.4 0.4 0.25 0.15 0.14 0.1
Table 1: Chemical Composition of 5083 Al – Alloy (wt. %)
Physical and Mechanical properties of 5083 Al-Alloy are
shown in Table.2 below:
Density
Tensile
Strength
Brinell
Hardness
Yield
Strength
Modulus of
Elasticity
2.65 315 75 228 72
Table 2: Physical and Mechanical Properties of 5083 Al-
Alloy
The filler wires used to transfer the extra material to fill the
gap between the joints of same composition of base metal.
There are different types of filler wires (5183, 5356, 5554,
5556 and 5654) available in the market on the basis of base
metal compositions of 5083 Al-Alloy. In this study, the filler
metal of 5183 graded is used for welding the specimens
because of its good.
Fig. 3: Filler Wire

3. Experimental and Finite Element Analysis of Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters
(IJSRD/Vol. 3/Issue 10/2015/137)
All rights reserved by www.ijsrd.com 641
The chemical compositions of 5183 filler wire are shown in
table 3:
Materials Mg Mn Si Fe Zn Cr Ti Cu
Al5183 4.55 058 0.1 0.27 0.06 0.11 0.11 0.01
Table 3: Chemical Composition of 5183 Filler Wire (Wt. %)
The physical and mechanical properties of 5183 filler wire
are shown in table 4:
Density(g/cc)
Melting
Range
Corrosion
Resistance
Hardness
2.65 1060-1175 Excellent 105
Table 4: Physical and Mechanical Properties of 5183 Filler
Wire
III. WELDED SPECIMEN
Two Al5083 aluminium alloy plates with a thickness of
5mm, and 200mm X 50mm (Length X Width) were
prepared for TIG welding. Make V-groove angle in each
specimens at 60o
of butt weld shown in fig.4.
Fig. 4: Single V-Butt weld
IV. FINITE ELEMENT MODEL
In this work, an aluminium alloy plate has been modelled as
a work piece. The basic transient thermal analysis and static
structural analysis performed using ANSYS 14.5 to
determine the temperature distribution, heat flux in the plate
and distribution of the stresses (von-mises stress), which has
a dimension of 400mmX50mmX5mm.
A. Meshed Model
The work pieces have been modelled using
CATIAV5R20.The coordinate system along x, y and z
direction and temperature, at each node. The element is
applicable to 3-D transient thermal analysis and static
structural analysis performed using ANSYS 14.5.
Fig. 5: Meshed Model
B. Boundary Conditions
The initial temperature of Al5083 Aluminium plate is
300
C.The initial condition of the plate can be created by
defining the predefined field in the load module. Convection
is heat transferred by moving fluid. The plate is static
position and the moving fluid is atmospheric air. The
atmospheric air is taking the heat from metal to bring the
metal equilibrium to surrounding temperature. In this
analysis combined convection and radiation film co-efficient
was used as convection film co-efficient. Heat convection
coefficients, h = 15 W/m2
-k as used surface film co-efficient
on the outer surface of the work piece and the bottom
surface of lower work piece with the ambient temperature of
300
C.
C. Load Conditions
Heat input is one of the most important process parameters
in controlling weld response. It can be referred to as an
electrical energy supplied by the welding arc to the
weldment.
In practice, however, heat input can approximately
be characterized as the product of the arc power supplied to
the electrode and voltage. Where, I is welding current; V is
welding arc voltage; v is the arc welding speed, and Q is the
heat input. In this work, the effect of heat input on welding
responses was evaluated using three values (heat input in
Watt), characterized as in the Table. V illustrates the values
used for the analyses. This evaluation was carried out by
considering the rest of parameter; Arc voltage was kept
constant at low value and restraint was kept constant at high
value.
Sr.
No
.
Distance(mm
)
Temp.
by
Expt.(0
C
)
Temp.
by
FEM(0
C
)
Percentag
e
Difference
1 10 213.35 204.49 8.86
2 20 192.55 185.11 7.44
3 30 171.89 165.72 6.17
Table 5: Comparison of Temperature Distribution by
experiment and FEM
Welding
current(I)
Arc
Voltage(V)
Welding
speed(v)
Heat
input(Q)
Heat
flux(q)
110 25 5.04 595 3.91e6
115 25 4.85 625 4.47e6
125 25 4.65 855 5.02e6
Table 6: Heat flux calculation for FEA

4. Experimental and Finite Element Analysis of Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters
(IJSRD/Vol. 3/Issue 10/2015/137)
All rights reserved by www.ijsrd.com 642
Fig. 6: Temperature distribution in welding plate by FEM
Fig. 7: Heat Flux in welding plate by FEM
Fig. 8: Stress distribution in welding plate by FEM
V. RESULT & DISCUSSION
A. Tensile Testing Results
The effect of welding input parameters on tensile strength of
the weld joint is discussed as below:
1) Effect of Welding Current on Tensile Strength of Weld
Joint
This phase reveals the effect of welding current of different
levels such as 110 amps, 115 amps and 125 amps on
mechanical properties of weld joint such as tensile strength.
Fig. shows the effect of welding current on tensile strength
of weld joint. As welding current increases at constant gas
flow rate, the tensile strength increases till optimum value of
125 amps current that shows the maximum tensile strength
of 130 MPa of weld joint.
Fig. 9: Welding current vs. Tensile strength
2) Effect of Gas Flow Rate on Tensile Strength of Weld
Joint
In this, the effect of shielding gas flow rate of 8 Lt/min, 9
Lt/min and 10 Lt/min of three different levels on mechanical
properties as a tensile strength of weld joint is describes.
Fig. shows the effect of gas flow rate on tensile strength of
weld joint at constant current. The tensile strength increases
by the variation of shielding gas in increasing order till an
optimum value of 9 Lt/min that shows the maximum tensile
strength of 130 MPa of weld joint.
Fig. 10: Gas flow rate vs. Tensile strength
3) Effect of Welding Speed on Tensile Strength of Weld
Joint
This phase reveals the effect of the different values of
welding speed on mechanical properties of weld joint such
as tensile strength. The effect of welding speed on tensile
strength of weld joint is shown below in Fig. The tensile
strength increases by increasing the welding speed at
constant current till optimum value of 4.85 mm/sec. at
current of 125 amps that shows the maximum tensile
strength of 130 MPa of weld joint. After that tensile strength
starts to decrease by further increment of welding speed
Fig. 11: Welding speed vs. Tensile strength
4) Hardness Testing
We are found out by considering the UTS as the reference
for the hardness results. The hardness testing is conducted
and the hardness of the various portion such as base metal,
weld metal and heat affected zone (HAZ) are found out for
Specimen A, Specimen E, Specimen I. From the results
obtained it is found that Specimen A is better with hardness
52 HB for base metal, 57 HB for heat affected zone, 30 HB
for weld meal.

5. Experimental and Finite Element Analysis of Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters
(IJSRD/Vol. 3/Issue 10/2015/137)
All rights reserved by www.ijsrd.com 643
Fig. 12: Hardness vs. Load
5) Finite Element Analysis
The results of the thermal analysis and structural analysis
conducted on specimens are shown below as in graph. By
using FEM methodology at different welding parameters the
residual stresses generated in the butt weld plate is
calculated. When the current of the weld plate is increase the
residual stresses are increases. When the welding speed is
increase the residual stresses are decreases.
Fig. 13: Comparison of Temperature Distribution by
experiment and FEM
Fig. 14: Temperature vs. Heat flux
Fig. 15: Stress vs. Heat flux
Fig. 16: Maximum residual stress vs. Arc time
The welding parameters combination of weld
specimen for minimum residual stress (325MPa) is current
110amp, voltage 25volt, welding speed 5.04 mm/sec.
The welding parameters combination of weld specimen for
maximum residual stress (389MPa) is current 125amp,
voltage 25volt, welding speed 4.65 mm/sec. Obtained.
ACKNOWLEDGMENT
We would like to acknowledge the support of Lab
Technician of mechanical department, Jabalpur Engineering
College, Jabalpur who had provided the resources regarding
testing machines. Mr. Gopal Singh Thakur had shared their
precious time and valuable information for the completion
of this work, utmost appreciation to the Almighty God for
the divine intervention in this endeavour.
VI. CONCLUSION
All the experimental trials are analysed under precautionary
measures in order to keep the error factors low and optimize
the reliability of results to produce the efficient weld joint
with 5083 Al-alloy specimens. The following conclusions
are drawn from the analysis of collected data of input and
output parameters:-
 Maximum tensile strength of 130 MPa is obtained at
welding current of 125 amps, gas flow rate of 9 Lt/min
and welding speed of 4.85 mm/sec.
 The tensile strength of weld joint in 5083 Al-alloy
plate increases by increasing welding speed up to an
optimum value of 4.85 mm/sec. for current of 125
amps and after that tensile strength decreases by
further increasing welding speed.
 The optimum range of input parameters are evaluated
as 125 amps of welding current, 9 Lt/min of gas flow
rate and 4.85 mm/sec. of welding speed by which
efficient weld joint is produced with good tensile
strength of weld joint.
In this work, a three dimensional finite element
model has been developed for Butt Welding Process, in
which a heat generation, temperature distribution and
residual stress were taken into consideration. This is cost
saving process because experimental processes are costly.
From the simulation results we also conclude that heat input,
welding speed has significant impacts on the weld response
which are as follows based on the present work, the
following conclusions can be made.

6. Experimental and Finite Element Analysis of Single-V Groove Butt Weld on Weld Pool Geometry of Aluminium Alloy Plate under Different Joint Parameters
(IJSRD/Vol. 3/Issue 10/2015/137)
All rights reserved by www.ijsrd.com 644
 A finite element computational investigation of a
single V-groove butt weld of an Al-Fe-Mg alloy
Al5083 is carried out.
 Methodology has been developed for a single V-
groove butt weld for the plate made up of Aluminium
Al5083 with dimensions 200mm x 50mm x 5 mm.
 As the speed of welding increases the stresses induced
in the plate decreases because as welding speed
increase for welding time decreases and thus it is noted
that the faster the welding speed is made, the less heat
is absorbed by the base metal and thus stresses induced
decreases.
 Welding parameters such as welding current and
welding speed has been varied from 110amp to
125amp; 4.65mm/sec. to 5.04mm/sec. to estimate the
residual stress using finite element analysis.
VII. SCOPE OF FUTURE WORK
The future scope of the study is discussed in steps such as
shown below
 In order to study the mechanical properties like tensile
strength and hardness, stress and temperature
distributions during welding, a number of other factors
can also be studied upon.
 In the present study, welding current, gas flow rate and
welding speed are taken into account as input
parameters. The other welding parameters such as arc
voltage, groove angle, heat input can be investigated on
same as well as different alloys of aluminium.
 Further, weld heat treatment can be applied on same or
different materials to achieve better results.
REFERENCES
[1] Ji-kun DING, Dong-po WANG, Ying WANG, Hui
DU. Effect of post weld heat treatment on properties of
variable polarity TIG welded AA2219 aluminum alloy
joints. Science Direct 24 (2014) 1307-1306.
[2] Izzatul Aini Ibrahim, Syarul Asraf Mohamat, Amalina
Amir, Abdul Ghalib. The effect of Gas metal arc
welding (GMAW) Processes on different welding
parameters. Sciverse Science Direct 41(2012)1502-
1506.
[3] Syarul Asraf Mohamat, Izatul Aini Ibrahim, Amalina
Amir. The Effect of Flux Core Arc Welding (FCAW)
Processes on Different Parameters. Sciverse Science
Direct 41(2012) 1497-1501.
[4] V. Balasubramanian, V. Ravisankar, G. Madhusudhan
Reddy. Effect of pulsed current welding on fatigue
behavior of high strength Aluminium alloy joints.
Science Direct 29 (2008) 492–500.
[5] Daniel Ramos-Jaime, Ismael Lopez Juarez, Pedro
Perez. Effect of process parameters on robotic GMAW
bead area estimation. Science Direct 7 (2013) 398 –
405.
[6] Her-Yueh Huang. Effects of activating flux on the
welded joint characteristics in gas metal arc welding.
Science Direct 31 (2010) 2488–2495.
[7] K.C. Ganesh, M. Vasudevan, K.R. Balasubramanian.
Modeling prediction and validation of thermal cycles,
residual stresses and distortion in type 316 ln stainless
steel weld joint made by TIG welding process. Science
Direct 86 (2014) 767 – 774.
[8] Q. Wang, D.L. Sun, Y .Na, Y. Zhou, X.L. Han, J.
Wang. Effects of TIG welding parameters on
morphology and mechanical properties of welded joint
of Ni base super alloy. Procedia Engineering 10 (2011)
37–41.
[9] João Roberto Sartori Moreno, Jefferson Luis Cesar
Sales. Characterization of cracks of welded joint of
ferrite stainless steel pipe. AISI 430 Journal of
Research in Mechanical Engineering. Volume 2, Issue
1 (2014).
[10] Fanrong Kong, Junjie Ma. Numerical and experimental
study of thermally induced residual stress in the
hybrid laser–GMA welding process. Journal of
Materials Processing Technology 211 (2011) 1102–
1111
[11] K. Suresh Kumar. Analytical modelling of temperature
distribution, peak temperature, cooling rate and
thermal cycles in a solid work piece welded by laser
welding process. Science Direct 6(2014) 821 – 834.
[12] Harinadh Vemanaboina, Ramesh Kumar Buddu.
Welding process simulation model for temperature and
residual stress analysis. Science Direct 6 (2014) 1539 –
1546.
[13] G.I. Mahiskar, A.P. Patil. Thermo-mechanical analysis
of multi-pass bead-on-plate welding Science Direct 5
(2014) 2522 – 2531.
[14] M. Zubairuddin, S.K. Albert. Influence of phase
transformation on thermo-mechanical Analysis of
modified 9Cr-1Mo Steel. Science Direct 5 (2014) 832
– 840.
[15] Aniruddha Ghosh, Somnath Chattopadhyaya. Effect of
heat input on submerged arc welded plate. Science
Direct 10 (2011) 2791–2796.
[16] M Jeyakumar, R. Narayanan Residual stress evaluation
in butt-welded steel plates. Indian Journal of
Engineering & material sciences.Vol.18, December
2011, pp.425-434.
[17] Shu Xua. Thermal stress analysis of dissimilar welding
joints by finite element method. Science Direct 15
(2011) 3860 – 3864.
[18] R.R. Ambriz, G. Barrera. A comparative study of the
mechanical properties of 6061-T6 GMA welds
obtained by the indirect electric arc (IEA) and the
modified indirect electric arc (MIEA). Materials and
Design 30 (2009) 2446–2453.
[19] OP Kanna. A text book of welding technology,
Dhanpat Rai Publications Ltd, 2006, P3.
[20] en.wikipedia.org/wiki/GTAW